Complete know-how in a single component

MAPAL has developed two sample components for the aerospace sector. These so-called ‘generic components’ cover all the demanding machining steps that may be involved in the production of hydraulic valve housings made from aluminum or torsion links for landing legs milled from titanium.

Wherever an aircraft system requires motion, there is a valve housing. Flaps, rudders, landing gear, engines and other components are controlled by hydraulics. Every plane therefore features many valve housings with different designs. They range from small boxes to blocks measuring half a metre. The machining requirements, however, are similar.

The generic component created by MAPAL measures around 300 x 300 x 300 mm and contains all machining steps that may be involved in manufacturing a valve housing, from pre-machining to finishing. It is deliberately not a replica of a customer component but was designed instead based on the machining requirements of various real-life parts.

Within the group of companies, MAPAL has compiled experience gained worldwide in the machining of such components. All this knowledge has been incorporated into a single sample component. This involves recommendations from the tool manufacturer for appropriate machining strategies and cutting data. Several different options are often available to solve a particular problem. Either a PCD tool or a fine boring tool can be used to ream a bore, while multi-bladed reamers present a further option. Each solution has its advantages. The decisive factor is always which advantages suit the customer’s situation.

Valve housings for aerospace are more complicated components than those used in other areas, such as hydraulics for construction machinery. MAPAL used over 130 different custom tools for a single housing type in the most complex customer project to date. Manufacturing often involves very thin-walled parts as it is important to minimize weight in the aviation industry. Other challenges include deep bores with cross bores or slots that create interrupted cuts. In addition, the machining of the aluminum used, with its low silicon content, produces very long chips that are difficult to break.

Another generic component that MAPAL has developed for the aerospace market is a torsion link for the main landing gear on the aircraft, which connects the two cylindrical parts of the landing leg. Its design allows the damper cylinder to retract and extend without twisting. This part is also available in various designs.

MAPAL uses its medium-sized sample part to model all real requirements. Due to the resulting high loads, torsion links are made of titanium. The low thermal conductivity of the material results in high temperatures during machining, which have a negative impact on tool life. In addition to optimized coating and cutting-edge preparation, the right machining strategy is essential here.

With its generic components for aerospace, MAPAL is pursuing a concept that has already proven its worth in the automotive sector. Here too, demanding components were identified which can be machined using the company’s tools. A large part of automotive technology is now covered by the appropriate generic components. With the help of generic components, MAPAL can also demonstrate its technological competency in the aerospace sector.